Cable Terminations, Joints, and Connectors

The Gala GXS-21 to GXS-25 kits join two lengths of 3-core XLPE or PVC insulated, shielded cable in the 24 kV equipment class: 12.7/22 kV, 8.7/15 kV and 11/11 kV, the class used on unearthed 11 kV networks. They are used for cable fault repairs, extensions and new underground feeders.

The joint rebuilds the cable layer by layer. Each core is connected with an inline ferrule and covered by stress control mastic, a black stress control sleeve, two red insulation tubes (six per kit at this voltage) and a red-and-black dual wall screened tube that restores insulation and semiconducting screen together. Copper woven mesh tape restores the core screens, a tinned copper braid carries earth across the joint, and a wraparound metallic joint case (or GI mesh) with heat shrinkable outer jacketing sleeves provides mechanical protection and sealing. Red mastic, worm drive clips and installation aids complete the kit.

Five kit codes cover cable sizes from 25-50 sq mm to 300-400 sq mm.

Gala holds a POWERGRID manufacturer approval and a MECON vendor registration for cable jointing and termination kits up to 33 kV.

Installation is with a gas torch after crimping the ferrules, following the illustrated instructions in every kit. Typical buyers are utilities' contractors and EPC firms on 22 kV and unearthed 11 kV networks, and industrial plants with 22 kV supply.

Manufactured by Gala in India. Datasheet and size selection on request.

The Gala GXO-31 to GXO-34 kits terminate 3-core XLPE or EPR insulated, shielded cable outdoors on 19/33 kV systems, the 36 kV equipment class. They are used where 33 kV cable meets an overhead line, an outdoor substation, a power transformer or outdoor switchgear.

At 33 kV, controlling electric stress and surface tracking matters most. Each core gets a stress control tube and stress control mastic at the screen cut, a red non-tracking weather-resistant tube over the insulation, and four rain sheds to lengthen the creepage path (twelve per kit). A non-tracking breakout seals the crutch, terminal sleeves and lug sealing tape seal the lugs, and armour and screen earthing sets, terminal lugs, mastics and installation aids complete the kit.

Four kit codes cover cable sizes from 25-50 sq mm to 240-400 sq mm. Indoor kits for the same cables are GXE-31 to GXE-34.

Gala holds a POWERGRID manufacturer approval and a MECON vendor registration for cable jointing and termination kits up to 33 kV.

Installation is with a gas torch, following the illustrated instructions supplied in every kit. Typical buyers are EPC contractors, utilities' contractors, industrial plants and substation builders working at 33 kV.

Manufactured by Gala in India. Datasheet and size selection on request.

An extensible ring main unit or gas-insulated switchgear panel is supplied with bushings on its side so that more panels can be coupled later. Until then those bushing ends are live parts exposed to dust, water and moisture, and they need sealing and insulating. Gala's bushing cap does this.

The cap is a red, heat-shrinkable moulding of cross-linked, non-tracking polyolefin with a closed, chamfered end. It is slipped over the bushing end and shrunk with a gas torch or hot-air gun so that it grips the bushing, seals out water and moisture and insulates it. It fits standard RMU and GIS bushings, and is supplied as an end sealing kit for the three bushings of a panel together with sealing mastic. When the panel is extended, the cap is removed from the bushing and the new connection is made.

Two sizes are made. GEK-401 has an internal diameter of at least 75 mm as supplied, recovers to 35 mm or less, and leaves a 4.0 mm insulation wall; GEK-501 opens to 100 mm and recovers to 45 mm with the same wall. Both are rated for 11 kV systems (12 kV equipment), shrink at 125 °C and work continuously from -40 °C to +100 °C. The non-tracking material and weather-resistant design give long service with little maintenance.

Manufactured by Gala in India. Datasheet and size selection on request.

In the cable-entry box of a ring main unit the phase-to-phase clearance is small, and air alone does not always give enough insulation. Humidity, dust, reptiles, rodents and birds can then trigger a flashover or a short circuit across the terminations. Gala's GTPE-500 cable terminal protector puts an insulating barrier around each terminal.

It is a one-piece moulded elastomer elbow with a C-type interface. It fits over the RMU's epoxy bushing and the cable termination and is closed at the front by a separate insulating plug. With the RMU de-energised and locked out, the installer cleans the termination, lug and bushing, greases the protector's inner sealing surface and the bushing with silicone grease, pushes the protector onto the bushing, feeds the cable and lug up through the lower leg, bolts the lug to the bushing through the front opening and presses the plug in until flush. The plug can be removed again, so the joint can be re-opened, voltage-tested directly and the protector re-used.

One size takes cables from 25 to 400 sq mm, including sector-shaped cores, and suits RMUs with compact C-type bushings for 11 kV systems. The moulded material is UV and track resistant, and every protector is factory tested. The GTPE-500 is an insulating barrier, not a touch-proof (screened) connector.

Manufactured by Gala in India. Datasheet and size selection on request.

On a CV line making XLPE power cable, the curing tube is kept under pressure while the cable passes through it, so the points where the cable enters and leaves the tube need a seal that grips the moving cable without damaging it. Gala's CV gasket is a consumable seal for that job.

The gasket is a moulded elastomer part in orange-red: a shallow cone rising from a flat outer flange to a large central opening. The flange carries six 9 mm bolt holes at 60 degree spacing and is bolted into the steel flange at the entry or exit of the curing tube; the cable passes through the centre of the cone. By holding the cable tight during production runs, the gasket keeps the curing pressure at the set level and reduces loss of process water or gas. It is used on both water-cooled and gas-cooled lines.

Gala describes the seal as long-lasting, resistant to abrasion, able to withstand high temperature and pressure, easy to handle and harmless to the cable's insulation and sheath surface.

Two sizes are made, GSES-1 S (180 mm overall) and GSES-1 (255 mm overall). The buyers are power cable manufacturers and CV line operators who replace these seals as wear parts. Gala is an ISO 9001, ISO 14001 and ISO 45001 certified manufacturer.

Manufactured by Gala in India. Datasheet and size selection on request.

When a cable's outer sheath is cut, scraped or crushed, the usual fixes mean cutting the cable or shutting the circuit down. Gala's Heat Shrink Cable Repair Sleeve (GMRS) avoids both. It is a flat sheet of cross-linked polyolefin with a hot-melt adhesive layer. It is wrapped round the damaged section where the cable lies, the overlap is closed, and the sleeve is heat-shrunk so that it tightens onto the cable while the adhesive melts and seals the damage. The result is a permanent waterproof barrier and mechanical protection over the repaired length.

Typical jobs are repairing damaged cable jackets, retrofitting protection over existing connections, repairing frayed cables and connectors in confined or underground spaces, and covering cable-to-conduit transitions and bundles of cable, wire or rope. It is used on communication, power, utility, industrial, shipboard and offshore cables.

Installation: roughen and degrease the cable jacket and the sleeve's inner overlap, wrap the sleeve so that the damage sits opposite the overlap, close the overlap, then shrink with a gas torch from the centre towards the edges until adhesive comes out at both ends, rolling out any wrinkles while hot.

Nine sizes cover cable outside diameters from 5 mm to 192 mm. Smaller sizes come in 100, 200 or 300 mm lengths, larger ones in 300 or 400 mm, with a minimum overlap of 25 to 75 mm. Custom dimensions are available on request. Stocking a few sizes covers most repair needs.

Manufactured by Gala in India. Datasheet and size selection on request.